Process and device for cooling and cleaning a casting

Abstract: In order to effectively enhance the overall efficiency in casting operations, a process and system for cooling and cleaning a casting is disclosed. The process and system include removing the casting from a molding machine after it has been formed. The casting is then moved to a punch-out station for removing it from a sand mold. Next, the casting is moved to a shake-out station for shaking residual sand from it. The casting is then conveyed away from the shake-out station on a cooling conveyor. Next, the temperature of the casting is monitored at or near a downstream end of the cooling conveyor. The casting is then transferred from the cooling conveyor into a vibratory cooling drum where it is further cooled. In addition to these unique aspects, the process and system includes controlling the rate of cooling of the casting within the vibratory cooling drum.

Description: The present invention is generally related to casting processes and systems and, more particularly, a process and system for cooling and cleaning a casting. Generally speaking, the processes and systems for the casting of metals can oe divided into two principal categories. The first of these involves casting with expendable molds, e.g., sand casting whereas the second category involves the utilization of permanent molds which can be reused a large number of times. In either case, it will be understood that it is necessary to initially make a model of the casting to be produced. As is well recognized, the model is called a "pattern" in the field of founding, and the mold is then produced from the pattern which may, by way of example, be formed of wood, plaster, metal, plastics and the like. With the exception of very simple castings, the pattern will generally include two or more parts, i.e., the actual pattern as well as the core or cores which will form the cavities and recesses in the casting. In casting with expendable molds, the molding materials used for constructing the actual molds in which the metal will be cast are usually mineral substances such as sand. The sand, along with bonding agents, give the molds the necessary strength and dimensional accuracy. Moreover, with the bonding agents which are commonly used, the bonding action may be achieved, depending upon the materials, by either drying or chemical consolidation (curing). In dry sand molding, it is generally known that the mold is baked whereas in green sand molding, the mold is typically utilized with sand in a damp, or "green" condition. The metal is then poured either into an open mold or through a system of channels in a closed mold. When the metal has solidified, the casting is removed from the mold, it then undergoes additional cooling, and the casting is finally cleaned by abrasive blasting, tumbling or the like. DE-A-3,100,028 describes a cooling tunnel for the controlled forced cooling of hot unpacked castings. US-A-3,627,020 describes apparatus in which sand molds containing castings are conveyed on a cooling conveyor to a mold-breaking station for breaking the molds and releasing the castings. Further advancement of the conveyor pushes the fractured mold and castings from the mold-breaking station onto a shakeout conveyor to complete the breakup of the sand mold whereby the castings can be removed. US-E-33,542 describes vibratory tumbling apparatus for the shake out of castings or the like. The apparatus comprises a horizontal contain carried by a frame resiliently mounted on a foundation. A vibration generator is carried by the container and produces a vibratory force to the container. Where the casting is an automotive cylinder block, it has been known that the cooling system or process is most unsatisfactory. It has commonly required an overhead cooling conveyor where the castings are partially cooled in a very slow five to six hour time span over a distance of approximately 1500 meters. Moreover, maintenance and repair that are involved in this system or process have represented a heavy burden for the foundry. Still additionally, the requirement for complementary equipment such as brushes, shake-out devices and shot blasting machines, have taken up unacceptably large amounts of valuable foundry space. The present invention is directed to overcoming one or more of the foregoing problems and achieving one or more of the resulting objects. It is a principal object of the present invention to provide an improved process and system for cooling and cleaning a casting. It is still an additional object of the present invention to provide such a process and system where cooling can be performed in a more efficient and effective manner than in the past. It is a further object of the present invention to provide a computer controlled process and system for any type of cylinder block casting. Accordingly, the present invention is directed to a process and system for cooling and cleaning a casting which includes removing the casting from a molding machine after it has been formed. The casting is then moved to a punch-out station for removing it from a sand mold. Next, the casting is moved to a shake-out station for shaking residual sand from the casting. The casting is then conveyed away from the shake-out station on a cooling conveyor. Next, the casting temperature is monitored at or near a downstream end of the cooling conveyor. The casting is then transferred from the cooling conveyor into a vibratory cooling drum for cooling. Still additionally, the process includes the step of controlling the rate of cooling of the casting within the vibratory cooling drum. In a preferred form of the invention, the temperature monitoring includes receiving a temperature signal indicative of the temperature of the casting at or near the downstream end of the cooling conveyor. Advantageously, the casting transfer also includes introducing molding sand from a point upstream of the cooling conveyor into the vibratory cooling drum with the casting. Preferably, the cooling rate control then includes adding moisture to sand within the vibratory cooling drum responsive to a signal indicative of the moisture in the sand. In other respects, the conveying of the casting preferably includes exhausting air from an upstream end of the cooling conveyor and blowing air onto a downstream end of the cooling conveyor. Similarly, cooling rate the control preferably includes exhausting air from a downstream end of the vibratory cooling drum at a point just upstream of a molding sand return port therein. In an exemplary form of the invention, the cooling rate control includes generating a thermocouple signal from each of a plurality of locations within the vibratory cooling drum. It also preferably includes adding moisture to sand within the vibratory cooling drum at each of a plurality of locations therewithin. As for the temperature monitoring, it preferably includes receiving an infrared signal indicative of temperature at a point just beyond the downstream end of the cooling conveyor. Advantageously, the molding sand including sand from the shake-out station are conveyed to the vibratory cooling conveyor along a path which is independent of the casting. When this is done, a scale signal is generated which is indicative of molding sand weight at a point downstream of the shake-out station and upstream of the vibratory cooling drum. In a most highly preferred application of the invention, the process and system is designed and particularly well suited for cooling and cleaning an engine casting. The cooling rate control advantageously includes the generation of a sand moisture signal from each of a plurality of locations within the vibratory cooling drum at which locations moisture is added to sand responsive to the signals. In this connection, the cooling rate control further advantageously includes processing the scale, temperature and sand moisture signals to control moisture addition to the sand. In this preferred application of the invention, the process and system may further include transferring the engine casting from the vibratory cooling drum to a continuous shot blast station at a point downstream thereof. Preferably, the engine casting is at a temperature of approximately 677 to 732° C (1250°F to 1350°F) and the molding sand is at a temperature of approximately 121°C (250°F) at the punch-out station. It is also advantageous to move the engine casting from the punch-out station to a soft shake-out station for shaking residual sand from the casting and later moving the casting to a core shake-out station at a point downstream of the cooling conveyor and upstream of the vibrartory cooling drum. As for other parameters, the sand temperature at the core shake-out station is approximately 427°C (800°F) and the engine casting temperature just upstream of the vibratory cooling drum is approximately 538°C (1000°F). In a most highly preferred application of the invention, the engine casting is removed from the vibratory cooling drum at a temperature of approximately 54.4°C (130°F) and the sand is removed from the vibratory cooling drum at a temperature of approximately 48.9°C (120°F) with a moisture content of approximately 1.5% Other objects, advantages and features of the present invention will become apparent from a consideration of the following specification taken in conjunction with the accompanying drawings. FIG. 1 is a schematic view illustrating a process and system for cooling and cleaning a casting in accordance with the present invention; and FIG. 2 is a schematic view illustrating a process and system similar to that illustrated in FIG. 1 which is especially suited for use with engine castings. In the illustrations given, and with reference first to FIG. 1, the reference numeral 10 designates generally a schematic representation of a process and system for cooling and cleaning a casting in accordance with the present invention. It includes removing the casting from a molding machine 12 after it has been formed, moving the casting to a punch-out station 14 for removing it from a sand mold, moving the casting to a shake-out station 16 for shaking residual sand from the casting, and conveying the casting away from the shake-out station 16 on a cooling conveyor 18. In addition, the process and system includes monitoring the temperature of the casting as at 20 at a point at or near a downstream end 18a of the cooling conveyor 18 following which it is transferred into a vibratory cooling drum 22. More specifically, the process and system includes transferring the casting from the cooling conveyor 18 into the vibratory cooling drum 22 for further cooling of the casting. It will also be understood that the process and system 10 includes controlling the rate of cooling of the casting within the vibratory cooling drum 22. For this purpose, a drum moisture addition control device 24 may be utilized to add moisture to sand within the vibratory cooling drum 22 responsive to a signal indicative of the moisture in the sand. Still referring to FIG. 1, the temperature monitoring is achieved by receiving a temperature signal as at 20 indicative of the temperature of the casting at or near the downstream end 18a of the cooling conveyor 18. It will also be seen and understood that the process and system include introduction of molding sand as at 26 from a point upstream of the cooling conveyor 18 into the vibratory cooling drum with the casting by means of a conveyor 28 which carries "strike off" and spill sand as well as sand received as at 30 from the shake-out station 16. As mentioned, the cooling rate control includes adding moisture to sand within the vibratory cooling drum 22 by means of the drum moisture addition control device 24 responsive to a signal indicative of the sand moisture. With this understanding of the process and system 10, the cooling rate control may also advantageously include the exhausting of air as at 32 from a downstream end 22a of the vibratory cooling drum 22 at a point just upstream of a molding sand return port 34 therein. In the exemplary embodiment, the cooling rate control includes generating a thermocouple signal from each of a plurality of locations 36, 38 and 40 within the vibratory cooling drum 22. These signals are advantageously generated by sensors 42, 44, and 46 which transmit their respective signals by means of a signal conveying line 48 which is in communication with the drum moisture addition control device 24 substantially as shown. As will also be seen, the cooling rate control includes adding moisture to sand within the vibratory cooling drum 22 at each of a plurality of locations 50, 52 and 54. In this connection, the moisture is advantageously added by means of appropriate fluid control valves 56, 58, and 60 that are suitably controlled by the drum moisture addition control device 24. These valves can, thus, open to add moisture to the sand within the vibratory cooling drum 22 at one or more of the locations 50, 52 and 54 depending upon the thermocouple signals received from the sensors 42, 44, and 46 which measure sand moisture content. Since the sand moisture content is dependent upon the temperature of the sand and casting, this is advantageous in controlling the rate of cooling of the sand and casting as they pass through the vibratory cooling drum 22. As previously mentioned, the temperature monitoring is preferably achieved by receiving a temperature signal as at 20 indicative of the temperature of the casting at or near the downstream end 18a of the cooling conveyor 18. This signal is preferably an infrared signal which is also transmitted to the drum moisture addition control device 24 by means of a signal conveying line such as 57. Still additionally, the process and system 10 includes the generation of a scale signal as at 59 which is indicative of the molding sand weight downstream of the shake-out station 16 and upstream of the vibratory cooling drum 22. With this understanding of the process and system 10, the cooling rate of the casting is suitably controlled by processing the scale, temperature and sand moisture signals to control moisture addition to the sand. Thus, it will be appreciated that the scale signal is transmitted from a scale as at 6 1 (which is positioned along the path of the "strike off", spill, and shake-out sand as it is conveyed toward the vibratory cooling drum 22) to the drum moisture addition control device 24 by means of a signal carrying line 62 where, along with sand moisture and temperature signals transmitted by lines 48 and 57, respectively, the drum moisture addition control device 24 can control moisture addition to the sand in the vibratory cooling drum 22 and, thus, control cooling of the casting therewithin. And as previously mentioned, air can be exhausted as at 32 from at or near the downstream end 22a of the vibratory cooling drum 22 to further control the cooling rate of the casting therewithin. While not previously mentioned, the process and system may include exhausting air as at 64 from an upstream end 18b of the cooling conveyor 18 and blowing air as at 66 onto a downstream end 18a of the cooling conveyor 18. This pattern of air circulation relative to the cooling conveyor 18 also serves to reduce the temperature of the casting as it passes from the shake-out station 16 to the vibratory cooling drum 22. As will be appreciated, all of these various cooling techniques cooperate in order to achieve the intended objective of cooling the casting most expeditiously without cracking or other damage thereto. In the embodiment of the invention which is illustrated in FIG. 1, the casting is at a temperature of approximately 677-732°C (1250°F to 1350°F) and the molding sand is at a temperature of approximately 121°C (250°F) at the punch-out station 14. It will also be seen that the casting may suitably enter the vibratory cooling drum 22 at a temperature of approximately 538°C (1000°F). Still additionally, the casting and sand may be removed from the vibratory cooling drum 22 at temperatures of approximately 54.4°C (130°F) and approximately 48.9°C (120°F), respectively, with the sand having a moisture content of approximately 1.5%. Referring to FIG. 2, the process and system 110 will be seen and understood to be generally quite similar to the process and system 10 illustrated and described in connection with FIG. 1. It includes the same basic steps and equipment by which a casting passes from a molding machine 112 to a punch-out station 114 and, from there, to a soft shake-out station 116 and onto a casting cooling conveyor 118 which preferably has air exhausted as at 164 at an upstream end 118b and blown onto the cooling conveyor as at 166 at a downstream end 118a thereof. As will also be seen, the molding sand including "strike off", spill and shake-out sand pass along a conveyor 128 to be introduced along with the casting into the vibratory cooling drum 122. While the process and system 10 illustrated in FIG. 1 is entirely satisfactory for almost any application, the process and system 110 is particularly well suited for utilization with engine castings. FIG.2 includes an additional step of moving the engine casting, which will typically comprise a cylinder block, to a sand core shake-out station 200 at a point downstream of the cooling conveyor 118 and upstream of the vibratory cooling drum 122. The sand temperature at the core shake-out station 200 is approximately 427°C (800°F) and the engine casting temperature is approximately 538°C (1000°F) as it enters the vibratory cooling drum 122. As will be appreciated, the process and system 110 causes the temperature of the casting to be monitored as at 120 which temperature is conveyed by a line 148 to a drum moisture addition control device 124. Also, as before, the process and system 110 includes the generation of thermocouple signals as at 136, 138, and 140 by means of sensors 142, 144, and 146 which are conveyed to the drum moisture addition control device 124 through the line 148. These thermocouple signals, along with the infrared temperature signal conveyed by means of the line 157 and the scale signal as at 159 from the scale 161 conveyed by means of the line 162, are all processed by the drum moisture addition control device 124. When the signals have been processed, the drum moisture addition control device 124 controls the valves 156, 158, and 160 for selectively introducing moisture as at 150, 152, and 154 into the sand in the vibratory cooling drum 122 to control the cooling rate of the engine casting. As in FIG. 1, the vibratory cooling drum 122 may also advantageously include an air exhaust 132, a molding sand return port 134, and all other details thereof. With this understanding, the process system 110 may also serve to reduce the temperature of the engine casting as it exits the downstream end 122a of the vibratory cooling drum 122 to 54.4°C (130°F) with the sand temperature being reduced to 48.9°C (120°F) and having a moisture content of approximately 1.5%. In both FIG. 1 and FIG. 2, the casting can then be introduced into a continuous shot blast for further cleaning as at 70 and 170, respectively. While not previously discussed in detail, it will be appreciated that the present invention is particularly suited for cooling a casting below a temperature of criticality to avoid cracking. The latter can be a serious problem, particularly if the casting comes into contact with moisture at an elevated temperature. In addition, since the moisture is added in an entirely controlled fashion, the casting is not only efficientiy and effectively cooled but the sand is homogenized and cooled as well. It will be appreciated that the drum moisture addition control device will comprise a computerized control system. It will include a processing unit for suitably processing the data in the form of the signals which are transmitted to it from the various sensors and the like. In this manner, the cooling of the casting in the vibratory cooling drum can be controlled as required to achieve rapid completion of the cooling process. In an experimental application, the time for cooling a casting from the point of removal from a molding machine to the point of transfer into a vibratory cooling drum was approximately 36 minutes. This time was found suitable for keeping all stress levels within production limits and, moreover, the subsequent desired temperature drop within the vibratory cooling drum was achieved in approximately 10 minutes in a drum length of approximately 12 meters. In the vibratory cooling drum, the castings will be understood to rotate within a rather thick layer of sand conveyed to the drum by a conveying belt from the upstream equipment. By reason of the probes and thermocouples in the drum, an exclusive moisture control system is achieved. Moisture is always added to the sand in the vibratory control drum, never to the surface of the castings themselves. Once cooled, the castings are subjected to continuous shot blast and the sand is returned into the system. Preferably, the vibratory cooling drum will take the form of the drums disclosed in my commonly owned U.S. Patent Nos. 4,926,601, granted on May 22, 1990 and Re. 33,542, granted on February 26, 1991. With the present invention, it has been possible to eliminate many pieces of equipment requiring high maintenance costs. It is also possible with the invention to cast any type of cylinder block without modifying cooling times and casting path. Still additionally, the present invention requires no manual assistance since it is entirely controlled by a computer. While in the foregoing there have been set forth preferred embodiments of the invention, it will be appreciated that the details herein given may be varied by those skilled in the art without departing from the scope of the appended claims.

Claims: A process for cooling and cleaning a casting, comprising the steps of: removing said casting from a molding machine (12,112) after said casting has been formed in said molding machine (12,112); moving said casting to a punch-out station (14,114) for removing said casting from a sand mold; moving said casting to a shake-out station (16,116) for shaking residual sand from said casting; conveying said casting away from said shake-out station (16,116) on a cooling conveyor (18,118); monitoring (20,120) the temperature of said casting at or near a downstream end (18a,118a) of said cooling conveyor (18,118); transferring said casting from said cooling conveyor (18,118) into a vibratory cooling drum (22,122) for cooling said casting; and controlling (24,124) the rate of cooling of said casting within said vibrtatory cooling drum (22,122). A process according to Claim 1, wherein said conveying step includes exhausting air (64,164) from an upstream end (18b,118b) of said cooling conveyor (18,118) and blowing air (66,166) onto a downstream end (18a,118a) of said cooling conveyor (18,118). A process for cooling a casting, comprising the steps of: monitoring (20,120) the temperature of said casting following the molding thereof including receiving a temperature signal (57,157) indicative of the temperature of said casting; transferring said casting along with molding sand from the molding thereof into a vibratory cooling drum (22,122) for cooling said casting and molding sand in said drum (22,122); and controlling (24,124) the rate of cooling of said casting within said vibratory cooling drum (22,122) including adding moisture (50,52,54;150,152,154) to molding sand responsive to a moisture indicative signal (48,148). A process according to any one of Claims 1 to 3, wherein said monitoring step (20,120) includes receiving a temperature signal (57,157) indicative of the temperature of said casting at or near said downstream end (18a,118a) of said cooling conveyor (18,118). A process according to any one of Claims 1 to 4, wherein said transferring step includes introducing molding sand (28,30;128) from a point upstream (18b,118b) of said cooling conveyor (18,118) into said vibratory cooling drum (22,122) with said casting. A process according to any preceding claim, wherein said controlling step (24,124) includes adding moisture (50,52,54;150,152,154) to sand within said vibratory cooling drum (22,122) responsive to a signal (48,148) indicative of the moisture in said sand. A process according to any preceding claim, wherein said controlling step (24,124) includes exhausting air (32,132) from a downstream end (22a,122a) of said vibratory cooling drum (22,122) at a point (22a,122a) just upstream of a molding sand return port (34,134) therein. A process according to any preceding claim, wherein said cooling rate controlling step (24,124) includes generating a thermocouple signal (48,148) from each of a plurality of locations (36,38,40;136,138,140) within said vibratory cooling drum (22,122). A process according to any preceding claim, wherein said cooling rate controlling step (24,124) includes adding moisture (50,52,54;150,152,154) to sand within said vibratory cooling drum (22,122) at each of a plurality of locations (50,52,54;150,152,154) therewithin. A process according to any preceding claim, wherein said temperature monitoring step (20,120) includes receiving an infrared signal (57,157) indicative of temperature at a point just beyond said downstream end (18a,118a) of said cooling conveyor (18,118). A process according to any preceding claim, wherein said molding sand including sand from said shake-out station (16,116) are conveyed to said vibratory cooling drum (22,122) independently of said casting. A process according to Claim 11, including the step of generating a scale signal (62,162) indicative of molding sand weight downstream of said shake-out station (16,116) and upstream of said vibratory cooling drum (22,122). A process according to Claim 12 dependent upon Claims 4 and 6, wherein said cooling rate controlling step (24,124) includes processing said scale, temperature and sand moisture signals (48,57,62;148,157,162) to control moisture addition to said sand. A process according to any preceding claim, including the step of transferring said casting from said vibratory cooling drum (22,122) to a shot blast station (70,170) at a point downstream thereof. A process according to Claims 1 or 2 wherein the casting is an engine casting and wherein: the step of moving the engine casting to a punch-out station (16,116) includes the engine casting being at a temperature of approximately 677 to 732°C (1250-1350°F), and moving molding sand from said molding (12,112) at a temperature of approximately 121°C (250°F) at said punch-out station (14,114); said shake-out station (16,116) is a soft shake-out station (16,116); the step of monitoring (20,120) includes receiving a temperature signal (57,157) indicative of the temperature of said engine casting at or near said downstream end (18a,118a) of said cooling conveyor (18,118); the step of transferring includes introducing molding sand from a point (28,30;128) upstream of said cooling conveyor (18,118) into said vibratory cooling drum (22,122) with said engine casting; the step of controlling (24,124) includes adding moisture (50,52,54;150,152,154) to sand within said vibratory cooling driven (22,122) responsive to a signal (48,148) indicative of the moisture in said sand and further including generating a sand moisture signal (48,148) from each of a plurality of locations (50,52,54;150,152,154) within said vibratory cooling drum (22,122) responsive thereto at each of a plurality of locations (50,52,54;150,152,154) therewith; and removing said engine casting from said vibratory cooling drum (22,122) at a temperature of approximately 54.4°C (130°F) and removing sand from said vibratory cooling drum (22,122) at a temperature of approximately 48.9°C (120°F) with a moisture control of approximate 1.5%. A process according to Claim 15, including the step of moving said engine casting to a core shake-out station (200) at a point downstream of said cooling conveyor (118) and upstream of said vibratory cooling drum (122), wherein said sand temperature at said core shake-out station (200) is approximately 427°C (800°F) and wherein said engine casting temperature just upstream of said vibratory cooling drum (22) is approximately 53 8°C (1000°F). A system for cooling a casting, comprising: a temperature monitor (20,120) for monitoring the temperature of said casting following the molding thereof and producing a temperature signal indicative of the temperature of said casting; a vibratory cooling drum (22,122) for cooling said casting and molding sand in said drum (22,122); and means (24,124) for controlling the rate of cooling of said casting within said vibratory cooling drum (22,122) by adding moisture (50,52,54;150,152,154) to molding sand responsive to a moisture indicative signal (48,148). A system according to Claim 17, wherein said controlling means (24,124) includes means (32,132) for exhausting air from a downstream end (22a,122a) of said vibratory cooling drum (22,122) at a point just upstream of a molding sand return port (34,134) therein. A system according to Claim 17 or to Claim 18, wherein said controlling means (24,124) includes a thermocouple signal generator (36,38,40;136,138,140) at each of a plurality of longitudinally spaced apart locations within said vibratory cooling drum (22,122). A system according to anyone of Claims 17 to 19, wherein said controlling means (24,124) includes a moisture insertion port (50,52,54;150,152,154) within said vibratory cooling drum (22,122) at each of a plurality of longitudinally spaced apart locations therewith. A system according to anyone of Claims 17 to 20, wherein said temperature monitor (20,120) produces an infrared signal (57,157) indicative of the temperature of said casting at a point just upstream of said vibratory cooling drum (22,122). A system according to anyone of Claims 17 to 21, including a signal generating scale (59,61;159,161) indicative of the weight of molding sand to be introduced into said vibratory cooling drum (22,122) at a point located just upstream thereof A system for cooling and cleaning an engine casting, comprising: a molding machine (12,112) for forming said casting in a sand mold therewithin; a punch-out station (14,114) for removing said engine casting from said sand mold; a shake-out station (16,116) for shaking residual sand from said engine casting; a cooling conveyor (18,118) for moving said engine casting from said shake-out station; and a cooling system according to anyone of Claims 17 to 22.

Inventors: MUSSCHOOT ALBERT, MUSSCHOOT, ALBERT
Applicants: GEN KINEMATICS CORP, GENERAL KINEMATICS CORPORATION
Application year: 1994
Main classification: B22D29
IPC codes: B22D46, B22D30, B22D29